Welding system with multiple user interface modules

ABSTRACT

A welding system user interface module includes a front panel comprising a first input device and a first display screen. The welding system user interface module also includes circuitry comprising a memory storing machine-readable instructions, a processor for executing the machine-readable instructions, and communication circuitry configured to receive UI data from the first input device or a second input device of a remote welding system user interface module, and to broadcast synchronized data to the first display screen and a second display screen of the remote welding system user interface module.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from and the benefit of U.S.Provisional Application Ser. No. 61/697,993, entitled “WELDING SYSTEMWITH MULTIPLE USER INTERFACE MODULES,” filed Sep. 7, 2012, which ishereby incorporated by reference in its entirety for all purposes.

BACKGROUND

The present invention relates generally to the field of welding systems,and more particularly to welding systems with multiple user interfacemodules that are synchronized.

In typical welding systems, user interface (UI) modules may appear inmany locations. However, the UI modules may each display different setsof information at the different locations. In some cases, a UI modulemay even display outdated information. This disconnect of informationwithin the system may result in conflicting settings, leading tooperator confusion.

BRIEF DESCRIPTION

In one embodiment, a welding system user interface module includes afront panel comprising a first input device and a first display screen.The welding system user interface module also includes circuitrycomprising a memory storing machine-readable instructions, a processorfor executing the machine-readable instructions, and communicationcircuitry configured to receive UI data from the first input device or asecond input device of a remote welding system user interface module,and to broadcast synchronized data to the first display screen and asecond display screen of the remote welding system user interfacemodule.

In another embodiment, a welding system includes a first user interfacemodule located on a first welding system component, and a second userinterface module located on a second welding system component. Datadisplayed by the first and second user interface modules issynchronized.

In another embodiment, a method includes receiving UI data from a firstuser interface module of a welding system or a second user interfacemodule of the welding system. The method also includes broadcastingsynchronized data to the first and second user interface modules basedat least in part on the received UI data.

DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a diagram of an embodiment of a welding system that mayutilize synchronized UI modules, in accordance with embodiments of thepresent disclosure;

FIG. 2 is a block diagram of an exemplary welding system includingvarious welding equipment and accessories, in accordance withembodiments of the present disclosure;

FIG. 3 is a front view of the upper UI module, in accordance withembodiments of the present disclosure;

FIG. 4 is a front view of the lower UI module, in accordance withembodiments of the present disclosure;

FIG. 5 is a perspective view of the welding torch of FIG. 1 having thetorch UI module, in accordance with embodiments of the presentdisclosure;

FIG. 6 is a block diagram of the welding power supply unit, the weldingwire feeder, and the welding torch of FIG. 1, illustrating exemplarycircuitry of the UI modules, in accordance with embodiments of thepresent disclosure; and

FIG. 7 is a flow chart of an exemplary method of control used by thecontrolling UI module of the welding system of FIG. 6, in accordancewith embodiments of the present disclosure.

DETAILED DESCRIPTION

The embodiments described herein include improvements to welding systemuser interface modules. Such improvements may provide consistent datathroughout all UI modules in the system, resulting in synchronized data(e.g., relating to operating parameters of the various welding systemcomponents, parameters relating to the welding process as a whole, andso forth) being provided to all of the components for improved weldingsystem operability. The UI modules enable an operator to adjust andmonitor the inputs and outputs of the welding system, which may bereceived from and distributed to multiple locations in a weldingenvironment. The welding system may include multiple UI modules onvarious components within the system, such as a welding power source, awelding wire feeder, a welding torch, a welding helmet, a welding remotedevice (e.g., a pendant), a welding cooling system, a personal computer(PC), and so forth. The UI modules may be specifically designed for thespecific components for which they are designed. However, the UI modulesmay include certain types of UI modules that may be interchangeably(e.g., removable and replaceable) used between various components of awelding system. In addition, UI modules within a welding system may besynchronized such that the data are always relatively synchronized(e.g., within a given updating period, such as less than 1 millisecond)across the various UI modules. For example, as described in greaterdetail below, in certain embodiments, one of the UI modules in a weldingsystem may always function as the synchronization module, receiving UIdata (e.g., data relating to manipulation of input devices, datarelating to changes in state for the particular UI module, data relatingto changes in system states, and so forth) from the various UI moduleswithin the welding system, and broadcasting synchronized data to thevarious UI modules.

Turning to the figures, FIG. 1 is a diagram of an embodiment of awelding system 10 that may utilize synchronized UI modules, inaccordance with embodiments of the present disclosure. It should beappreciated that, while the welding system 10 described herein isspecifically presented as a gas metal arc welding (GMAW) system 10, thepresently disclosed synchronized UI modules may also be used with otherarc welding processes (e.g., FCAW, FCAW-G, GTAW, SAW, SMAW, or similararc welding processes). More specifically, as described in greaterdetail below, all equipment and accessories used in the welding system10 may include the synchronized UI modules described herein. The weldingsystem 10 includes a welding power supply unit 12 (i.e., a welding powersource), a welding wire feeder 14, a gas supply system 16, and a weldingtorch 18. The welding power supply unit 12 generally supplies power tothe welding system 10 and other various accessories, and may be coupledto the welding wire feeder 14 via a weld cable 20 as well as coupled toa workpiece 22 using a lead cable 24 having a clamp 26. In theillustrated embodiment, the welding wire feeder 14 is coupled to thewelding torch 18 via a weld cable 28 in order to supply welding wire andpower to the welding torch 18 during operation of the welding system 10.In another embodiment, the welding power supply unit 12 may couple anddirectly supply power to the welding torch 18.

In the embodiment illustrated in FIG. 1, the welding power supply unit12 may generally include power conversion circuitry that receives inputpower from an alternating current power source 30 (e.g., the AC powergrid, an engine/generator set, or a combination thereof), conditions theinput power, and provides DC or AC output power via the weld cable 20.As such, the welding power supply unit 12 may power the welding wirefeeder 14 that, in turn, powers the welding torch 18, in accordance withdemands of the welding system 10. The lead cable 24 terminating in theclamp 26 couples the welding power supply unit 12 to the workpiece 22 toclose the circuit between the welding power supply unit 12, theworkpiece 22, and the welding torch 18. The welding power supply unit 12may include circuit elements (e.g., transformers, rectifiers, switches,and so forth) capable of converting the AC input power to a directcurrent electrode positive (DCEP) output, direct current electrodenegative (DCEN) output, DC variable polarity, or a variable balance(e.g., balanced or unbalanced) AC output, as dictated by the demands ofthe welding system 10 (e.g., based on the type of welding processperformed by the welding system 10, and so forth).

The illustrated welding system 10 includes a gas supply system 16 thatsupplies a shielding gas or shielding gas mixtures to the welding torch18. In the depicted embodiment, the gas supply system 16 is directlycoupled to the welding torch 18 via a gas conduit 32 that is part of theweld cable 20 from the welding power supply unit 12. In anotherembodiment, the gas supply system 16 may instead be coupled to thewelding wire feeder 14, and the welding wire feeder 14 may regulate theflow of gas from the gas supply system 16 to the welding torch 18. Ashielding gas, as used herein, may refer to any gas or mixture of gasesthat may be provided to the arc and/or weld pool in order to provide aparticular local atmosphere (e.g., shield the arc, improve arcstability, limit the formation of metal oxides, improve wetting of themetal surfaces, alter the chemistry of the weld deposit, and so forth).

In addition, in certain embodiments, other welding equipment and weldingaccessories (e.g., welding-related devices) may be used in the weldingsystem 10. For example, in most welding applications, a welding helmet34 may be worn by an operator of the welding system 10. The weldinghelmet 34 provides protection to the operator of the welding system 10,particularly protecting the eyes of the operator from the flashingassociated with the welding arc during welding operations. In addition,in certain embodiments, the welding helmet 34 may provide feedback tothe operator related to parameters of the welding operations. Forexample, the welding helmet 34 may include an internal displayconfigured to display the welding parameters to the operator during thewelding operations. In addition, in certain embodiments, a weldingremote device (e.g., a pendant) 36 may be used to communicate betweenthe welding wire feeder 14 and the welding torch 18. The welding remotedevice 36 is a device that may be used at a welding application remotefrom an associated welding power supply unit 12 and/or welding wirefeeder 14, yet still provide substantially the same display and inputdevices that the remote welding power supply unit 12 and/or welding wirefeeder 14 provide. In other words, the welding remote device 36 may beused as a remote control panel when it is not feasible or practical touse control panels on an associated remote welding power supply unit 12and/or welding wire feeder 14.

The welding equipment and accessories illustrated in FIG. 1 are merelyexemplary and not intended to be limiting of the types of weldingequipment and accessories that may be used in the welding system 10 andinclude synchronized UI modules as described herein. Many other types ofwelding equipment and accessories (e.g., welding cooling systems,personal computers (PCs), and so forth) may also be used in conjunctionwith the welding system 10 and include synchronized UI modules asdescribed herein. As will be appreciated, welding systems 10 maysometimes become somewhat complex with the number of welding equipmentand accessories that are included in the welding systems 10. Forexample, FIG. 2 is a block diagram of an exemplary welding system 10including various welding equipment and accessories, including a weldingpower supply unit 12, a wire feeder 14, a welding torch 18, a weldinghelmet 34, and welding remote device 36, a welding cooling system 44,and a personal computer (PC) 46, in accordance with embodiments of thepresent disclosure. As will be appreciated, each of the welding systemcomponents of FIG. 2 may be configured to receive one or more of the UImodules 38, 40, 42 in specific locations. For example, as illustrated inFIG. 1, the welding power supply unit 12 may be configured to receive anupper UI module 38 in an upper front panel, and to receive a lower UImodule 40 in a lower front panel. Similarly, the welding wire feeder 14may be configured to receive an upper UI module 38 in a front panel. Thewelding torch 18 may be configured to receive a torch UI module 42 in atop body portion. In certain embodiments, the welding helmet 34 may beconfigured to receive one of the UI modules 38, 40, 42 in an interiorportion of the welding helmet 34 to enable the operator to view theinformation. In other embodiments, a UI module may be specificallydesigned (e.g., having different functionality than any of the UImodules 38, 40, 42) for use within the interior portion of the weldinghelmet 34. The welding remote device 36 may be configured to receive oneof the UI modules 38, 40, 42 (or a UI module specific designed for thewelding remote device 36) in a front panel. Returning now to FIG. 2, thewelding cooling system 44 and the PC 46 may be configured to receive oneof the UI modules 38, 40, 42 in a front panel.

As illustrated in FIG. 2, the communication paths between the variouswelding equipment and accessories can become somewhat complex. Inparticular, any number and combination of the welding system componentsof FIG. 2 may be used together. The synchronized UI modules describedherein facilitate synchronized communication of data between suchwelding equipment and accessories. More specifically, as describedabove, the embodiments described herein provide synchronized UI modulesthat may be specifically designed for the specific welding equipment andaccessories for which they are designed. However, the UI modules areinterchangeable (e.g., are removable and replaceable) between certainwelding equipment and accessories. For example, returning now to FIG. 1,for purposes of illustration herein, the illustrated welding system 10includes an upper UI module 38, a lower UI module 40, and a torch UImodule 42, each of which may have specific input devices and displaydevices for the specific type of UI module. For instance, the torch UImodule 42 is specifically designed for welding torches such as thewelding torch 18 illustrated in FIG. 1 and, as such, may generallyinclude a smaller physical profile having fewer and more streamlinedinput devices and display screens than, for example, the upper and lowerUI modules 38, 40. As also illustrated in FIG. 1, both the welding powersupply unit 12 and the welding wire feeder 14 include upper UI modules38, whereas only the welding power supply unit 12 includes a lower UImodule 40. However, in other embodiments, the welding wire feeder 14 maybe configured to receive a lower UI module 40 instead of an upper UImodule 38, or may be configured to receive both an upper UI module 38and a lower UI module 40. It will be appreciated that the UI modules 38,40, 42 illustrated in FIG. 1 are merely exemplary and not intended to belimiting. Other types of synchronized UI modules may be used.

As described above, the UI modules 38, 40, 42 may include differentinput devices and display screens (e.g., plasma panels, LCDs panels, LEDpanels, and so forth), which generally depend upon the generalfunctionality of the welding equipment or accessory for which the UImodule is used. For example, FIG. 3 is a front view of the upper UImodule 38, FIG. 4 is a front view of the lower UI module 40, and FIG. 5is a perspective view of the welding torch 18 of FIG. 1 having the torchUI module 42, in accordance with embodiments of the present disclosure.As illustrated, the upper UI module 38 generally includes more inputdevices than the lower UI module 40. For example, the upper UI module 38includes two control knobs 48, whereas the lower UI module 40 onlyincludes one control knob 48. These control knobs 48 may be used tocontrol parameters of the welding process, such as voltage, current,wire feed speed, welding wire diameter, and so forth. Similarly, theupper UI module 38 includes considerably more control buttons 50, whichmay be used to modify operating modes, modes of information display, andso forth. Furthermore, the upper UI module 38 includes a power button52, which may be used to turn the respective welding equipment ofaccessory on or off, whereas the lower UI module 40 does not include apower button 52. However, the lower UI module 40 includes memory buttons54 that may be used to store certain operation profiles (e.g., a certainmemory profile may include a given set of operating parameters, such asvoltage, current, wire feed speed, welding wire diameter, and so forth).The displays are also somewhat different between the upper UI module 38and the lower UI module 40. In certain embodiments, the display screens56 of the upper UI module 38 may be display screens for displayingoperating parameters (e.g., voltage, current, wire feed speed, weldingwire diameter, and so forth) as they change during operation of thewelding system 10, and the display screen 58 of the lower UI module 40may be a display screen (e.g., touch screen) that may be scrolledthrough by the operator to view various information of the weldingsystem 10.

In contrast to the upper and lower UI modules 38, 40, the torch UImodule 42 illustrated in FIG. 5 includes a relatively smaller displayscreen 60 (e.g., plasma, LCD, LED, touch, etc.). The torch UI module 42may include control buttons 62 (e.g., soft keys, hard buttons, knobs,etc.). As will be appreciated, the functionality of these controlbuttons 62 may be relatively simpler than that of either the upper UImodule 38 or the lower UI module 40. However, the torch UI module 42 mayenable the operator to adjust system parameters quickly (e.g., withouthaving to walk over to the welding power supply unit 12 or the weldingwire feeder 14), resulting in more efficient welding processes.

All of the various input devices (e.g., the control knobs 48, thecontrol buttons 50, the power buttons 52, the memory buttons 54, thecontrol buttons 62, and so forth), as well as various other inputdevices that may be included in the UI modules 38, 40, 42, may be usedto receive user inputs from the operator from the various weldingequipment and accessories to which the UI modules 38, 40, 42 areattached. In addition, as described in greater detail below, the variousdisplay screens 56, 58, 60 may display information that has beensynchronized between the various UI modules 38, 40, 42. The operator maychange and/or view any of the welding system settings from any of the UImodules 38, 40, 42 in the welding system 10. As such, the UI hardware,software, and data may be duplicated at every UI module 38, 40, 42 inthe welding system 10. Therefore, each UI module 38, 40, 42 may displaythe same information, and only one set of data may need to be managedand relayed to each UI module 38, 40, 42. Using duplicated data at eachUI module 38, 40, 42 may result in synchronized data throughout thewelding system 10, reducing the possibilities for mistakes and/orconfusion. Furthermore, the welding system 10 may be able to receiveinput information at multiple locations and have the informationrecognized across the entire welding system 10 immediately (e.g., withina given updating period, such as every 100 milliseconds). Additionally,the synchronization mechanism may enable locking and/or limiting ofsystem parameters, improving the security of the welding system 10.

FIGS. 3-5 primarily illustrate the outwardly-facing front panels of theUI modules 38, 40, 42. However, each of the UI modules 38, 40, 42includes its own circuit board that includes circuitry for processing UIdata (including data relating to user manipulation of user inputdevices) from their respective input devices, communicating informationrelating to the UI data among the various UI modules 38, 40, 42,receiving updated (e.g., synchronized) data relating to operation of thewelding process, displaying the received data on their respectivedisplay screen(s), and so forth. In general, one of the UI modules 38,40, 42 will be used as a controlling UI module. In other words, one ofthe UI modules 38, 40, 42 will be used to receive information relatingto the UI data from all of the UI modules 38, 40, 42 of the weldingsystem 10, and to communicate updated (e.g., synchronized) data relatingto operation of the welding system 10 to the various UI modules 38, 40,42, thereby synchronizing operation of the various UI modules 38, 40,42. In general, the UI modules 38, 40, 42 include substantially similarhardware and/or software, such that any one of the UI modules 38, 40, 42could be used as the controlling UI module. It will be appreciated thatselection of a specific UI module 38, 40, 42 as the controlling modulemay be selected via the input devices of the various UI modules 38, 40,42.

FIG. 6 is a block diagram of the welding power supply unit 12, thewelding wire feeder 14, and the welding torch 18 of FIG. 1, illustratingexemplary circuitry of the UI modules 38, 40, 42, in accordance withembodiments of the present disclosure. In the illustrated embodiment,the upper UI module 38 of the welding power supply unit 12 is being usedas the controlling UI module. More specifically, the upper UI module 38of the welding power supply unit 12 receives UI data from the lower UImodule 40 of the welding power supply unit 12, the upper UI module 38 ofthe welding wire feeder 14, and the torch UI module 42 of the weldingtorch 18, and broadcasts synchronized data to the lower UI module 40 ofthe welding power supply unit 12, the upper UI module 38 of the weldingwire feeder 14, and the torch UI module 42 of the welding torch 18, aswell as updating its own input device(s) and display screen(s) with thesynchronized data. However, again, any one of the UI modules 38, 40, 42could be selected as the controlling UI module insofar as each of the UImodules 38, 40, 42 includes substantially similar hardware and/orsoftware, enabling each to function as the controlling UI module in themanner the upper UI module 38 is functioning in FIG. 6.

For example, as illustrated in FIG. 6, each of the UI modules 38, 40, 42includes a circuit board 64 that includes a memory 66, a processor 68,and communication circuitry 70. As described herein, in general, each ofthe UI modules 38, 40, 42 includes only a single circuit board 64 thatis associated with certain input devices and/or display screens.However, in certain embodiments, a composite UI module may be used,which includes a first UI module that includes certain input devicesand/or display screens and a first circuit board 64 that includes itsown memory 66, processor 68, and communication circuitry 70, and asecond UI module that includes certain input devices and/or displayscreens and a second circuit board 64 that includes its own memory 66,processor 68, and communication circuitry 70.

Each of the UI modules 38, 40, 42 includes machine-readable instructionsstored in the respective memory 66 that may be executed by therespective processor 68. The machine-readable instructions of thecontrolling UI module (the upper UI module 38 of the welding powersupply unit 12 in FIG. 6) determines the synchronized data to bebroadcast to the other UI modules 38, 40, 42 of the welding system 10based at least on UI data received from the UI modules 38, 40, 42 of thewelding system 10. The synchronized data that is broadcast may bedetermined at least in part on data that is communicated to/from controlcircuitry 72 that is internal to the welding system component (thewelding power supply unit 12 in FIG. 6) on which the controlling UImodule is located. Indeed, the communication circuitry 70 of each of theUI modules 38, 40, 42 may be configured to communicate with controlcircuitry 72 that is internal to (e.g., within a housing of) the weldingsystem component on which the UI module 38, 40, 42 is located, eitherwirelessly or via communication ports on the respective circuit board 64that are configured to mate with complementary ports in the respectivewelding system component. It will be appreciated that certain weldingsystem components (e.g., the welding torch 18) may not include suchinternal control circuitry 72 in certain embodiments.

The communication circuitry 70 of the UI modules 38, 40, 42 maysimilarly include either wireless or wired communication circuitry forcommunicating between the UI modules 38, 40, 42. For example, in certainembodiments, the communication circuitry 70 may use Ethernet, RS485,RS232, SPI, fiber optics, RF, or any other suitable communicationmethods to communicate the UI data and the synchronized data between theUI modules 38, 40, 42. In addition, in certain embodiments, the UImodules 38, 40, 42 may also communicate (e.g., via WiFi or othersuitable communication techniques) with a personal computer (PC) (e.g.,the PC 46 illustrated in FIG. 2), tablet computer, smart phone, and soforth, to provide a virtual user interface to a remote operator.Furthermore, in certain embodiments, the synchronized data may becommunicated across different communication technologies, and beformatted accordingly. Use of these communication methods may enable thewelding system components to communicate quickly, and may provideincreased welding system security from unauthorized users.

FIG. 7 is a flow chart of an exemplary method 74 of control used by thecontrolling UI module (e.g., the upper UI module 38 of the welding powersupply unit 12 of FIG. 6) of the welding system 10, in accordance withembodiments of the present disclosure. In step 76, the controlling UImodule broadcasts synchronized data to the UI modules 38, 40, 42 of thewelding system 10, wherein the synchronized data includes a broadcasttoken embedded therein. In step 78, the controlling UI module receivesUI data from input devices of the UI modules 38, 40, 42 of the weldingsystem 10, wherein the UI data includes a response token embeddedtherein. The response tokens are generally related to the broadcasttokens. For example, the response tokens may match the broadcast tokens,or may be related to (e.g. may include a counter, be an inverse, and soforth) the broadcast tokens. In step 80, the controlling UI modulereconciles conflicts between UI data based on the tokens, which mayinclude timestamps, counters, or a combination thereof. For example, afirst user input command (e.g., via manipulation of a user input device)received from one UI module 38, 40, 42 may occur at substantially thesame time as a second user input command (e.g., via manipulation of auser input device) received from another UI module 38, 40, 42. Based atleast in part on the response tokens that are embedded within thepotentially conflicting user input commands, the controlling UI moduledetermines which of the user input commands should take priority,whether both user input commands should be implemented, and so forth.This determination may be made based at least in part on communicationwith the control circuitry 72 internal to the welding system componenton which the controlling UI module is located. In addition, thereconciliation of the UI data (e.g., user input commands) may bedetermined by an arc controller (e.g., system root), which may beinternal to one of the welding system components. Furthermore, incertain embodiments, the reconciliation of the UI data (e.g., user inputcommands) may also include prioritization of the UI data (e.g., userinput commands). For example, a prioritization between the UI data maybe based on the types of the UI modules 38, 40, 42 (e.g., certain typesof UI modules 38, 40, 42 may be given higher prioritization), the typeof welding system component on which the UI module 38, 40, 42 is located(e.g., certain types of welding system components may be given higherprioritization), a location of the UI module 38, 40, 42 (e.g., based ona network address), and so forth, each of which may be embedded withinthe response tokens. Once the potentially conflicting UI data (e.g.,user input commands) are reconciled by the controlling UI module, themethod continues back to step 76 where the controlling UI module againbroadcasts synchronized data to the UI modules 38, 40, 42 of the weldingsystem 10.

As described above, each cycle of the method 74 may be performed by thecontrolling UI module at a given time interval (e.g., at leastapproximately every second, at least approximately every 100milliseconds, at least approximately every 50 milliseconds, at leastapproximately every 10 milliseconds, at least approximately every 1millisecond, or even more frequently). However, in certain embodiments,the rate at which the synchronized data is re-broadcast will change overtime. For example, the rate at which the synchronized data isre-broadcast may be reduced when there are no new changes to thesynchronized data (e.g., when the broadcast token stays the same betweencycles). However, when a change in the synchronized display data occurs(e.g., due to system behavior or new control values), the re-broadcasttime is momentarily sped up to ensure that each receiving display node(e.g., the UI modules 38, 40, 42) receives the update more rapidly. Thebroadcast rate reduction logic reduces the total number of networkmessages that the UI modules 38, 40, 42 have to process. For example, incertain embodiments, three broadcast display data messages including thesynchronized data may be sent within approximately 1 millisecond (e.g.,approximately 400 microseconds apart), and then the broadcast ratereduces to only once every 50 milliseconds (e.g., a baseline broadcastrate). In certain embodiments, the broadcast rate can also be increasedwhile actively welding (e.g., from approximately 50 milliseconds toapproximately 10 milliseconds or approximately 20 milliseconds). Assuch, the controlling UI module of the welding system 10 may vary thebroadcast rate to optimize network performance and to ensure promptdisplay updates. In particular, the broadcast rate may be varied basedon single occurrences or frequencies of occurrences of changes causedby, for example, manual changes via the input devices of the UI modules38, 40, 42 and/or automatic changes such as system state or feedbackchanges.

The modularity of the UI modules 38, 40, 42 described herein enablesrelatively complex welding systems, such as the welding system 10illustrated in FIG. 2, to provide appropriate types of synchronized datawith minimal types of interchangeable UI modules 38, 40, 42. Forexample, as illustrated in FIG. 6, the welding power supply unit 12 mayinclude system root control circuitry 72 that enables it to function asa network master and to control data management and automation of thewelding system 10. The control circuitry 72 may have no input devices ordisplay screens, however, the welding power supply unit 12 may includeboth a “basic UI” (e.g., the upper UI module 38) and an “advanced LCDUI” (e.g., the lower UI module 40). In addition, the welding wire feeder14 may include control circuitry 72 that provides basic local controlfunctionality for the welding wire feeder 14 and the “basic UI” (e.g.,the upper UI module 38). In addition, as described above, the weldingtorch 18 may include a “specialized LCD UI” (e.g., the torch UI module42). Returning to FIG. 2, the welding helmet 34 may include aspecialized UI module in an interior portion of the welding helmet 34.The welding remote device 36 may include the “basic UI” (e.g., the upperUI module 38), the “advanced LCD UI” (e.g., the lower UI module 40), ora specialized UI module. Similarly, the welding cooling system 44 andthe PC 46 may include the “basic UI” (e.g., the upper UI module 38), the“advanced LCD UI” (e.g., the lower UI module 40), or a specialized UImodule. Other types of welding system components, such as a diagnosticsservice tool and simple accessories (e.g., foot pedals and handcontrols) may include simple specialized UI modules with reducedfunctionality.

Furthermore, in certain embodiments, remote control nodes may be usedthat include no display screens or input devices, but nevertheless mayreceive and apply the synchronized data that is broadcast by thecontrolling UI module. Such remote control nodes may still be capable ofsending data to the controlling UI module. For example, a current ortemperature sensor may function as a remote control node, and may sendcontrol messages to the controlling UI module, and receive thesynchronized data as control values or state changes. In addition,automation or programmable logic controllers (PLCs) may use the same UIsynchronization messages (e.g., in the synchronized data) toautomatically adjust settings as a sequence of welded parts are changed,for example.

As described above, the modularity and interchangeability of the UImodules 38, 40, 42 described herein enable virtually unlimitedcombinations of UI functionality. Again, it should be noted that the UIhardware, software, and even the data communicated, of the UI modules38, 40, 42 are substantially identical, enabling each of the UI modules38, 40, 42 to function as a controlling UI module or simply a node inthe communication network of welding components of the welding system10. In addition, all of the UI modules 38, 40, 42 will have the samelook and feel as well as data management style. However, each of the UImodules 38, 40, 42 may individually display, at the same time, the exactsame parameters, some of the same parameters and some differentparameters, or entirely different parameters, depending on the specificneeds of the particular UI modules 38, 40, 42. For all UI modules 38,40, 42 that are displaying the same parameters, they match and aresynchronized. For example, if one display screen changes a parameterthat is on other display screens, the other display screens update asthe parameter changes. For all UI modules 38, 40, 42 that are displayingparameters that are not currently on other UI modules 38, 40, 42, someparameters may be edited with no affect to the other UI modules. Incertain embodiments, all of the upper UI modules 38 may display exactlythe same parameters. For example, if a change is made to what is beingdisplayed on one upper UI module 38, all of the upper UI modules 38 willbe updated to match what is being displayed. Conversely, all of thelower UI modules 40 display may be independent from each other, anddisplay the same or different parameters. For example, if a change ismade to what is being displayed on one lower UI module 40, the otherlower UI modules 40 may not necessarily follow (e.g., the data displayedmay be synchronized, but the particular parameters being displayed maynot be). It will be understood that any grouping of UI modules 38, 40,42 may have differing functionality. For example, in other embodiments,the upper UI modules 38 may potentially display different parameters,while the lower UI modules 40 may display exactly the same parameters.The parameter values themselves, however, will always be synchronizedregardless of the UI module 38, 40, 42 upon which they are displayed.

While only certain features of the invention have been illustrated anddescribed herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes as fallwithin the true spirit of the invention.

The invention claimed is:
 1. A welding system, comprising: an interfacecomprising a first display screen and a first input device configured toreceive first inputs from an operator to adjust one or more weldingsystem parameters; communication circuitry configured to receive, from aremote welding system user interface module, second inputs to adjust theone or more welding system parameter settings; processing circuitry; anda memory storing machine-readable instructions, which, when executed bythe processing circuitry, cause the processing circuitry to: synchronizethe one or more welding system parameter settings received from thefirst inputs and the second inputs; and transmit the synchronizedwelding system parameter settings to the first display screen and asecond display screen of the remote welding system user interfacemodule.
 2. The welding system of claim 1, wherein the machine-readableinstructions comprise instructions for reconciling conflicts betweenwelding system parameter settings received from the first and secondinput devices.
 3. The welding system of claim 2, wherein thesynchronized welding system parameter settings comprises a broadcasttoken, and the second inputs are associated with a response token,wherein reconciliation of the conflicts between the first inputs and thesecond inputs is based at least in part on the broadcast token and theresponse token.
 4. The welding system of claim 3, wherein the responsetoken comprises prioritization information.
 5. The welding system ofclaim 1, wherein the communication circuitry is configured tocommunicate with control circuitry internal to a welding systemcomponent.
 6. The welding system of claim 1, wherein the welding systemuser interface module is removable and replaceable from a welding systemcomponent.
 7. The welding system of claim 1, wherein the communicationcircuitry comprises wireless communication circuitry configured tocommunicate with the remote welding system user interface modulewirelessly.
 8. The welding system of claim 1, wherein the communicationcircuitry is configured to broadcast the synchronized welding systemparameter settings at least approximately every 100 millisecond.